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Steam Boilers
heyve been with us for over two hundred years, and most of the time, theyre so reliable most folks dont give them much thought. They sit in buildings all over the world, transferring heat from fuel to water, allowing us to warm our buildings or complete our processes. Steam boilers are simple, efficient and reliable. No machine does a better job of moving BTUs from one place to another. Weve used them for space heating since before the United States Civil War in 1861. Even before the Civil War, we used steam boilers for industrial processes. Today we use them to run factories, press clothes, wash dishes, pasteurize milk, sterilize medical equipment, and to heat entire cities! Their capabilities seem endless. But despite its simplicity, any steam boiler can run into trouble if its control system doesnt act properly. If the energy you put into the boiler exceeds what the boiler can absorb, the boiler can rupture. So you must always be on guard. A simple safety relief valve of the right capacity and relief-pressure setting protects the boiler from over pressure. But over pressure isnt the only thing that can threaten a steam boiler. There are also the dangers of dry firing. Should the internal water level drop too low, the boiler can burn out. So here too, you must always be on guard. You see, a steam boiler needs its water to move the heat away from its metal surfaces. Without the right internal level of water, heat quickly accumulates. Too much heat creates a very dangerous operating condition. Boiler manufacturers have always set up minimum safe water level requirements for their equipment. Our controls help enforce those requirements in two ways: By maintaining a minimum safe water level in the boiler. By signaling the burner to stop should the water level drop below that point. In this brief Systems Guide we will explain how we do these two very important jobs.
Rating). This is a law of physics so it doesnt vary from manufacturer to manufacturer. If youre working with a boiler with a rating of, say, 1,000,000 BTU/HR, you can be assured the water is turning to steam and leaving that boiler at the rate of about two gpm. And its leaving at speeds measured in miles per hour (sometimes exceeding 60 mph!). So its very important for your nearboiler piping to be correct. If its not, the fast moving steam will pull water out of the boiler and create problems for you in the system and the boiler. As the water (in the form of steam) heads out toward the system, the water level in the boiler will, of course, drop. How far it drops, depends a lot on the size and condition of your piping system. You see, ideally, the water should begin to return to the boiler before the boilers internal water line drops to a critical point. Thats the point at which the low water cut-off will cut power to the burner, or an automatic water feeder will open. Because the water is in the system piping and radiating during operation, the normal water level becomes a point thats somewhere in the lower-third of the gauge glass (Fig. C). Remember, youre working with a range of operation here, not a fixed point. If the water were to stay at the top of the gauge glass all the while the burner was firing, you probably wouldnt be making steam! So dont get too caught up with the word normal because the only thing thats normal is that the water level will rise and fall. Boiler manufacturers, as we said before, do establish a minimum safe water level for their boilers, however. That point is usually just out of sight of the bottom of the gauge glass. Should the water level drop to this point, the boiler may be in danger of overheating. We have to find a way to protect the boiler from itself (Fig. D). All leading authorities and insurance companies recognize this need. The ASME Code for Low Pressure Heating Boilers, for instance, specifies, Each automatically fired steam or vapor steam boiler shall be equipped with an automatic low water fuel cut-off. The device the code refers to is what most people in the field commonly call a low water cut-off. Its job is to stop the burner and protect the boiler.
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Here are a few good places to start: The air vents are dirty, not seating properly, and passing steam to the atmosphere. Someone left the boiler blowdown valve partially open. Someone, for whatever reason, has been drawing hot water from the boiler. The relief valve has discharged. The condensate pump isnt working as it should. The float may have come loose. The condensate may be too hot to pump. (Check those steam traps!) Improper near-boiler piping may be throwing water up into the system, or causing the waterline to tilt during operation. The wet returns may be leaking. (Always suspect any buried pipe). A check valve may be stuck closed or partially closed. The boiler may be foaming and priming. Check the pH of the water. It should be between 7 and 9. Check the condition of the water. Dirty water will prime and foam. Check the burners firing rate. Over-firing can cause priming. The pipes may not be properly pitched. The automatic feeder may not be working properly. Its chamber may be filled with sediment. Its feed line may be clogged. All of the condensate may not be returning from the system (a common problem with process applications). The boiler metal may be corroded and leaking at the water line. Flood the boiler to its header to check for leaks. Good troubleshooters take the time to look over the entire system before deciding whats wrong. Take the time to do it right, and youll be the person with the answers.
he best way to prevent overheating damage to a boiler is to stop the burner if the water level falls too low. This is the low water cut-offs job. There are several types of low water cut-offs you can use. Lets look at them.
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The water level in the low water cut-offs chamber will mimic the water level in the boiler. As the water level drops in the boiler during steaming, the level in the chamber, and the cut-offs float drops with it. Should the float drop to the boilers critical low water cut-off point, the float will trip an electrical switch thats wired in series with the burner. The burner instantly stops firing. It will stay off until the water level rises to a safe operating point. This happens when the condensate returns from the system or when an automatic water feeder or a boiler attendant adds water to the boiler. When the level reaches a safe position, the low water cut-off will make its electrical connection and the burner will restart. When a steam system is well balanced, the low water cut-offs job is to stand by and wait. The situation we just described suggests that theres something out of balance in that system. Well look at this again in a few minutes.
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incorporating delay features in the probes operating logic. These include a delay on break feature (DOB) which keeps the burner lit for 10 seconds after water leaves the probe. This minimizes the effects of a surging water line. Another addition the delay on make feature (DOM) allows an additional feed time of 15 seconds once water comes in contact with the probe. This minimizes rapid burner and feeder cycling by slightly elevating the water level so that water lost to steaming will return (in the form of condensate) before the water level drops below the probe. Float Type In operation, these are similar to the external, float operated low water cut-offs we looked at before. The difference is that instead of sensing a duplicated water level outside the boiler, these units sense the level directly inside the boiler. We make them for you in five mounting-barrel sizes (Series 69) to accommodate different boiler insulation thicknesses. When you select a built-in, float type control make sure it fits as far as possible into the boiler, without the float shield coming contact with the boiler. When a low water cut-off stops a burner, it also stops the entire heating system. Nothing will happen until the water in the boiler returns to a safe operating level. While this is very good for the boiler, it may not be the best thing for the system. If the heat in the building is off for too long a time, water pipes may begin to freeze. This is where automatic water feeders come in. An automatic feeder will maintain a safe minimum water level in the boiler and keep it operating, even if the system is leaking. It keeps the system operating automatically until you can make the repairs.
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A mechanical feeder can also protect a boiler (Fig. I) should a fuel-regulating device malfunction, causing the burner to lock in and stay there. Or suppose someone jumps-out a control, putting the burner on continuous operation. A mechanical automatic water feeder will continue to feed the boiler whenever the level drops to the feed point. Under normal circumstances, the electrical low water cutoff (the second part of the feeder/cut-off combination) is always standing by, ready to shut off the burner should something go wrong with the automatic feeder. An automatic water feeder doesnt feed at the two-thirds full point on the gauge glass. You set this by hand when you first start the system. As we said before, the normal level will range up and down as the system operates. An automatic feeder will maintain a safe minimum water line only. By doing this, it will lessen the possibility of human error. Consider this. A boiler attendant might put too much water in a steam boiler. He doesnt have an automatic feeder and hes tired of checking the water level every day so he fills the boiler to the two-thirds full point while its operating. When the condensate returns, the boiler floods. By adding water the attendant has limited the boilers steam-making space. Without enough room to break free of the water, the steam will now carry water up into the system piping. This leads to higher fuel bills, uneven heating, water hammer, scale formation in the boiler and burner short-cycling. Suddenly, problems plague this system, and no one is sure why. Automatic water feeders help you avoid these problems. They watch that water level, maintaining a safe minimum. They allow the boiler water line to rise and fall naturally through its normal operating range.
Steam Boiler
Burner On
Return Main
Burner On
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boiler. How much water will enter the boiler depends on several things, but there will always be enough to keep the boiler operating at a safe minimum water level. Once it has added the right amount of water, the feeder closes. While this is happening, the burner continues to run because the feeder keeps the boiler from dropping to its low water cut-off point. The Low Water Cut-Off Stops the Burner But suppose something happens and the automatic water feeder cant keep up with the rate at which the boiler is losing water. Suppose, for instance, that a pipe breaks or someone opens a boiler drain, causing the boiler to suddenly lose water. Should this happen, the water level will drop to a preset point, and the automatic feeder/cut-off combination will instantly cut power to the burner, shutting it down and protecting the boiler from a dry-firing condition. Though the burner is off, the automatic feeder will continue to add water to the boiler in an attempt to restore a safe minimum water level (Fig. L). As you can see, a combination mechanical water feeder and electrical low water cut-off provides you with boiler protection even if the power fails or something goes wrong in the burner circuitry.
Burner Off
Combination Water Feeders and Low Water Cut-Offs for Larger Boilers
As we said earlier, all steam boilers evaporate water at the rate of one-half gpm per 1,000 square feet EDR (240,000 BTU/HR). To satisfy a larger boilers needs, an automatic water feeder must be able to match the boilers higher steaming rate. If the feeder cant keep up, the burner will suffer from nuisance low water shutdowns. To avoid this problem, we make automatic feeder/cut-off combinations with wider flow orifices to meet the special needs of larger boilers. The operation of these larger units is the same as the ones we just looked at. The key difference is the increased flow rate (Fig. M). Once the larger feeder/cut-off combination satisfies the boilers minimum water line needs, it has to be able to close against the force of the city water pressure moving through that extra wide orifice. This calls for considerable float and lever power, and it explains why our feeder/cutoff combinations for larger boilers are bigger than those for smaller boilers. Weve carefully engineered them to get the maximum closing force in the space we have to work with. This ensures the unit will close tightly once its done its job (Fig. N). Codes call for larger boilers to have their gauge glasses mounted on water columns, rather than directly into the boiler. Consequently, we make our larger automatic
Burner On
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water feeders and feeder/cut-off combinations without quick hook-up fittings. Instead, we give these larger combinations one-inch (25mm), float chamber tappings so you can mount them directly on an equalizing line.
Fig. O
Steam Boiler
Float Switch
Single Boiler
Balanced System
Fig. P
ost two-pipe steam systems, and some one-pipe steam systems, need help returning condensate to the boiler (Fig. P). The pumps job is to provide the push the water needs to get back into the boiler. The water leaves the boiler as steam, condenses into a liquid in the radiators and piping, and flows by gravity into a
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condensate receiver. When the water level inside the receiver reaches a certain point, an electrical float switch turns the pump on. The pump quickly moves the water out of the receiver and back into the boiler. Steam boilers served by condensate pumps also need low water protection, and our low water cut-offs serve that purpose well. You can also use an automatic water feeder or a combination feeder/cut-off on these systems. But before you do, make sure the system is well balanced. What we mean by well balanced is that the condensate pump should be able to return the water to the boiler before the boilers water level drops to a point where the low water cut-off or automatic feeder goes into action. If the automatic water feeder adds water to the boiler (to maintain a safe minimum operating level), and then the condensate pump returns its water to the boiler, the boiler will most likely wind up with too much water. This excess water limits the boilers steam making space. Without enough room to break free of the water, the steam can carry water up into the system piping. That leads to higher fuel bills, uneven heating, water hammer, scale formation in the boiler and burner short cycling. So before you use an automatic water feeder on a steam boiler thats served by a condensate pump, check to see if the system is well balanced. It should run through its cycles without going off on low water. In other words, the condensate pump should balance the flow of water back into the boiler before the level drops to the critical, low water point. Keep in mind that a system with a condensate pump can become unbalanced if the returns clog with sediment or if any steam traps fail in an open position. Good troubleshooters always keep their eyes wide open.
controller recognizes the need and starts the pump. When the boiler water returns to the proper level in the gauge glass, the pump controller stops the pump. Should the pump not be able to keep up with the boilers need for water, the pump controller will sense this as well. The second switch (set at the lower of the two levels) will cut the electricity to the burner and protect the boiler from a low water condition (Fig. R). Feed water enters the system through a make-up water feeder in the boiler feed pumps receiver. If you wish, you can add a feeder/cut-off combination to operate at a level a bit lower than the pump controller. This will give you a mechanically operated feeder, which will act as a backup should something go wrong with the pump controller. It will also give you a secondary low water cut-off. Its like having a belt and suspenders for your boiler!
Pump Control and Low Water Cut-Off
City Water Supply Steam Boiler Burner On Boiler Feed Pump Make-Up Water Feeder
Boiler Feed Tank
Single Boiler
Unbalanced System
Fig. Q
Single Boiler
Feeder/Cut-Off Combination Unbalanced System
Fig. R
Multiple Boiler Systems with a Boiler Feed Pump and Motorized Return Valves
Here we have two boilers served by a single boiler feed pump (Fig. S). One boiler may be a stand by to the other, or they may be sharing the total load. For piping purposes, wed handle either application the same way. Notice how the condensate returns are independent. Each flows from the boiler feed pump receiver to the boiler through a motorized valve. This is an important detail. If you were to interconnect the returns, the water from one boiler would flow into the other. Steam Moves Remember, steam is dynamic, not static. Water doesnt seek its own level when the steam is moving out of the boiler. The slightest difference in firing rate or piping pressure drop between the two boilers will cause one to flood and the other to shut down due to a low water condition. This is why those independent returns are important. Were using motorized valves on this installation (Fig. S) to isolate one boiler from the other. When either boiler needs water, the McDonnell & Miller pump controller on that boiler will drop to a point where it will close the higher of its two switches. That switch will power that boilers motorized valve, causing it to open. When its fully opened, the motorized valve will trip an end switch and start the boiler feed pump. Water will flow only to the boiler that needs it. The float in the pump controller will sense the rising water. When the water reaches the proper level, the pump controller will break the electrical connection to the motorized valve. The valve will begin to close, shutting off the boiler feed pump as it does. As you can see, when we pipe multiple boilers this way it doesnt matter how big or small each is. The boiler feed pump, although sized for the total needs of all the boilers, will satisfy the needs of each in turn, no matter what size. Keeping the Water Flowing Weve installed a make-up water feeder in the boiler feed pumps receiver tank. Its job is to maintain a minimum water line in the tank so the pump will always have a reservoir from which it can draw feed water. In this system, all the water will enter the boilers through the boiler feed pump. If, for any reason, the boiler feed pump cant keep up with the boilers rate of evaporation, the water line in the boiler will drop. The lower switch in the McDonnell & Miller pump controller will stop the burner.
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Pump Control and Low Water Cut-Off City Water Supply Make-Up Water Feeder
Multiple Boilers
Boiler Feed Pump and Motorized Valves
Fig. S
City Water Supply Feeder Cut-Off Pump Controller Combination Pump Controller Feeder Cut-Off Combination
Make-Up Water Feeder Steam Boiler No.1 Motorized Valve Steam Boiler No.2 Motorized Valve
Burner On
Multiple Boilers
Boiler Feed Pump, Motorized Valve & Water Feeders
Fig. T
Motor Operated Proportioning Valve High Water Balancing Cut-Off and Alarm Valve
Motor Operated Proportioning Valve High Water Balancing Cut-Off and Alarm Valve
Multiple Boilers
Boiler Feed Pump, Electric Proportioning Regulators and Motorized Valves
Fig. U 22
If you find the pump suddenly cant keep up with the boilers needs, check the temperature of the returning condensate. As thermostatic radiator steam traps and end of main F&T traps age and fail, they pass steam into the returns. That can make the condensate hot enough to flash when it hits the pumps impeller. Boiler feed pumps cant move water once it has flashed to steam. The pump will turn and cavitate, but it wont satisfy the boiler. Ideally, in a low pressure steam heating system, the condensate in the pumps receiver shouldnt be hotter than 180F (82C).
Multiple Boiler Systems with a Boiler Feed Pump, Motorized Return Valves and Electric Proportioning Regulator (Fig. U)
Here were controlling the water lines with electric proportioning regulators. Were matching the incoming feed water to the exact amount of water thats leaving as steam. By doing this, were able to maintain a precise water line in both boilers and take advantage of each boilers full steaming space. There are times when steaming loads will vary tremendously. This is especially true of steam heating systems in larger buildings. We often set up these buildings to operate on outdoor air temperature sensors and night set-back devices. When the system first starts in the morning the boilers will steam longer than they will during the day when the pipes and radiators are hot. This is also true of seasonal operation when you run the heating system less often. This is when proportioning regulators can make a big difference. By closely monitoring the water line, regardless of varying system conditions, you improve the quality of steam leaving the boiler and allow the system to operate more efficiently.
Multiple Boiler Systems with a Boiler Feed Pump, Motorized Return Valves and Boiler Water Feeders (Fig. T)
This is the same system we just looked at, except weve added a combination automatic water feeder and low water cut-off to a point just below the pump controller. The feeder/cut-offs job will be to add water mechanically to the boiler should something happen to the boiler feed pump (for instance, if its cavitating because the return condensate is too hot). Think of the feeder/cut-off as a back-up device to keep the boiler in operation should something go wrong elsewhere. The low water cut-off will back up the pump controllers primary low water cut-off should something go wrong there, or if the feeder cant keep up with the boilers rate of evaporation for some reason.
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Receiver sizing is more an art than a science. You have to look closely at the entire system to figure out how long it will take the condensate to return from the building. There are many variables to consider: The type and condition of steam traps, the pitch and cleanliness of steam mains and returns, the pipe insulation or lack of it, the shape of the building and how people use it. There are also the times when youll have to deal with condensate transfer pumps, or maybe a vacuum/condensate pump. These pumps collect and relay return water back to the boiler feed pump. There are many things that can affect how quickly these secondary pumps move condensate back to the primary boiler feed pump. You have to consider them all when youre sizing a feed pump receiver. One thing will be a constant, however. There must always be enough water in the receiver for the boiler to draw from during the start-up cycle (the time between initial steaming and the return of condensate from the building). A McDonnell & Miller make-up feeder, set at the one-third full point on the receiver tank, will meet the boilers needs during this crucial start-up time. Lets take a closer look at these.
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BASIC
SYSTEM
OPERATION
BASIC SYSTEM OPERATION
Needle Valve
Fig. W
Motorized Valve
Model 93 Controller
Fig. X
Fig. Y 25
ow water protection isnt just for steam boilers. Hot water boilers face the same perils of overheating damage if the water line drops too low. Many people dont think of this as often as they should because hot water boilers serve closed systems. They have pressure reducing valves that are supposed to feed water automatically should a leak develop.
The truth, however, is that a pressure reducing valve is no substitute for a low water cut-off. Pressure reducing, or feed valves, often clog with sediment and wind up not feeding at all. A buried pipe can corrode and spring a leak that flows faster than a feed valve can satisfy. Relief valves can pop and, while dumping water at a great rate, actually prevent the feed valve from operating. Lets take a closer look at how we can protect these boilers.
On systems with buried pipes (say, a radiant heating system) a feed valve will open if a pipe breaks. It will feed fresh water continuously until it either clogs (and stops feeding) or destroys the ferrous components of the system with oxygen corrosion. A simple feed valve can wind up costing a lot more than its purchase price. This is why major suppliers of feed valves, such as ITT Bell & Gossett, recommend you close the feed valve once youve established your initial fill pressure. This is also why we strongly recommend you use a low water cut-off on every hot water boiler. Feed valves are not a substitute for low water cut-offs. They can't protect your boilers from a low water condition. Feed valves are fine for filling the system initially, and for helping you vent air from the radiators. But once the system is up and running, you shouldnt look to them for protection.
Series 850 or 900 Low Water Cut-Offs Supply Main ASME Relief Valve
Return Main
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Over firing
There are times when hot water boilers dont lock-out on safety. Whether by control failure or human error, things go wrong. And when they go wrong in a hot water heating system, the water temperature can rise quickly to a point where the compression tank cant take up the expansion of the water. This causes the relief valve to discharge. When the relief valve opens, theres a sudden drop in system pressure. The water, which at this point is probably much hotter than 212F (100C), will flash into steam. This is why ASME insists that relief valves for hot water boilers carry steam-discharge ratings. If a feed valve doesnt open to replace this rapidly exiting water, a low water condition will quickly result. The only thing that can protect the boiler at this point is a low water cut-off. The feed valve cant protect the boiler because its typical setting is 12 psig (.83 bar). In other words, the system pressure must drop below 12 psig (.83 bar) before the feed valve will open. The trouble is that while the relief valve is open and flashing steam to atmosphere, the internal system pressure never drops anywhere near 12 psig (.83 bar). A relief valve with a 30 psig (2.1 bar) setting, for instance, will open at 30 psig (2.1 bar), and close again when the pressure drops to about 26 psig (1.79 bar). The result is a loss of water with no make-up. Repeat this cycle enough times and the boiler will be in a dangerous, low water condition. Keep in mind, steam exerts pressure. It can easily fool a feed valve, and thats why feed valves offer very little protection at all against low water.
Series PS-851 Probe Type Low Water Cut-Off Fig. BB Series 67 Float Type Low Water Cut-Off Fig. AA
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Feeder/Cut-Off Combinations for Cast Iron and Steel Hot Water Boilers (Fig. DD)
To protect a boiler from dry firing, the low water cut-off must located above the boilers crown. After the low water cut-off shuts off the burner, you should have a way to add water to the system to ensure the crown stays under water. A combination water feeder and low water cut-off can do this for you. If you position the feeder above the boilers crown, it will mechanically feed water if the level should drop to that point. This is an important consideration because, even if the electricity is cut off, its possible for the firing cycle to continue if the fuel feed valve is mechanically locked open. The combination units cut-off switch will act as a back-up to the primary low water cutoff, providing the boiler with additional protection.
Compression Tank
City Water Supply Feeder Cut-Off Combination Model 247-2, 51-2, 51-S-2, 53-2 Water Level
;; ;; ;; ;
Burner On
Series 850 or 900 Low Water Cut-Offs Supply Main ASME Relief Valve
;; ;;
Return
Circulating Pump Flow Switch Pressure Reducing Valve with Built-in Check Valve Return from System Relief Valve Zone Control Valves
Flow
ood engineering practice calls for every hot water boiler to have a pressure relief valve. This springloaded valve must be able to release the boilers entire load at the boilers maximum operating pressure. Here are some things that can cause a relief valve to open in a hot water heating system: The automatic feed valve fails, allowing higher than normal pressure to enter the system. Someone leaves a hand bypass line open after filling the system. Someone hydrostatically tests the system at a pressure greater than the relief valves setting. The air cushion in the diaphragm type compression tank doesnt match the systems static fill pressure. Keep in mind, most tanks come from the factory precharged at 12 psig (.83 bar). If the system needs more than 12 psig (.83 bar) pressure, you have to add more air to the tank, and you have to do this while you have the tank disconnected from the system. The compression tank may be too small for the system. The boilers aquastat is in a well without heat transfer grease. When this happens, the boilers temperature will quickly exceed the aquastats setting, causing rapid rise in system pressure. The circulator may be on the return side of the system with the compression tank at its suction. If it is, the circulators head pressure will appear inside the boiler as a net increase. It may be enough to open the relief valve. The burner limit may be jumped-out or stuck in a manual position. The main thing to keep in mind when youre troubleshooting this one is that relief valves pop when any of these three things happen: The compression tank loses its air cushion The system takes on more water. The system temperature increases. Think methodically, and keep your eyes wide open!
e hope this Basic System Operation Guide has given you insight into the systems on which youre now working or will face in the future. We welcome any questions or comments you may have about the Guide, or about our products.
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